Alloy composition for lithium ion batteries

ABSTRACT

Alloy compositions, lithium ion batteries, and methods of making lithium ion batteries are described. The lithium ion batteries have anodes that contain an alloy composition that includes a) silicon, b) aluminum, c) transition metal, d) tin, e) indium, and f) a sixth element that contains yttrium, a lanthanide element, an actinide element, or a combination thereof. The alloy composition is a mixture of an amorphous phase that includes silicon and a crystalline phase that includes an intermetallic compound of 1) tin, 2) indium, and 3) the sixth element.

RELATED APPLICATION

This application claims priority from U.S. Provisional Application No.60/702,244, which was filed on Jul. 25, 2005 and is hereby incorporatedby reference.

FIELD OF INVENTION

Alloy compositions for lithium ion batteries are described.

BACKGROUND

Rechargeable lithium ion batteries are included in a variety ofelectronic devices. Most commercially available lithium ion batterieshave anodes that contain materials such as graphite that are capable ofincorporating lithium through an intercalation mechanism duringcharging. Such intercalation-type anodes generally exhibit good cyclelife and coulombic efficiency. However, the amount of lithium that canbe incorporated per unit mass of intercalation-type material isrelatively low.

A second class of anode material is known that incorporates lithiumthrough an alloying mechanism during charging. Although these alloy-typematerials can often incorporate higher amounts of lithium per unit massthan intercalation-type materials, the addition of lithium to the alloyis usually accompanied with a large volume change. Some alloy-typeanodes exhibit relatively poor cycle life and coulombic efficiency. Thepoor performance of these alloy-type anodes may result from theformation of a two-phase region during lithiation and delithiation. Thetwo-phase region can create internal stress within the alloy if onephase undergoes a larger volume change than the other phase. Thisinternal stress can lead to the disintegration of the anode materialover time.

Further, the large volume change accompanying the incorporation oflithium can result in the deterioration of electrical contact betweenthe alloy, conductive diluent (e.g., carbon) particles, and binder thattypically form the anode. The deterioration of electrical contact, inturn, can result in diminished capacity over the cycle life of theanode.

SUMMARY

Alloy compositions, lithium ion batteries, and methods of making lithiumion batteries are provided. More specifically, the lithium ion batterieshave anodes that contain an alloy composition that is a mixture of anamorphous phase and a nanocrystalline phase.

In one aspect, a lithium ion battery is described that contains acathode, an anode, and an electrolyte that is in electricalcommunication with both the anode and the cathode. The anode includes analloy composition that contains (a) silicon in an amount of 35 to 70mole percent, (b) aluminum in an amount of 1 to 45 mole percent, (c) atransition metal in an amount of 5 to 25 mole percent, (d) tin in anamount of 1 to 15 mole percent, (e) indium in an amount up to 15 molepercent, and (f) a sixth element that includes yttrium, a lanthanideelement, an actinide element, or a combination thereof in an amount of 2to 15 mole percent. Each mole percent is based on a total number ofmoles of all elements except lithium in the alloy composition. The alloycomposition is a mixture of an amorphous phase that includes silicon anda nanocrystalline phase that includes tin, indium, and the sixthelement.

In another aspect, a method of making a lithium ion battery is describedthat includes preparing an anode that contains an alloy composition,providing a cathode, and providing an electrolyte that is in electricalcommunication with both the anode and the cathode. The alloy compositioncontains (a) silicon in an amount of 35 to 70 mole percent, (b) aluminumin an amount of 1 to 45 mole percent, (c) a transition metal in anamount of 5 to 25 mole percent, (d) tin in an amount of 1 to 15 molepercent, (e) indium in an amount up to 15 mole percent, and (f) a sixthelement that includes yttrium, a lanthanide element, an actinideelement, or a combination thereof in an amount of 2 to 15 mole percent.Each mole percent is based on a total number of moles of all elementsexcept lithium in the alloy composition. The alloy composition is amixture of an amorphous phase that includes silicon and ananocrystalline phase that includes tin, indium, and the sixth element.

In yet another aspect, an alloy composition is described. The alloycomposition contains (a) silicon in an amount of 35 to 70 mole percent,(b) aluminum in an amount of 1 to 45 mole percent, (c) a transitionmetal in an amount of 5 to 25 mole percent, (d) tin in an amount of 1 to15 mole percent, (e) indium in an amount up to 15 mole percent, and (f)a sixth element that includes yttrium, a lanthanide element, an actinideelement, or a combination thereof in an amount of 2 to 15 mole percent.Each mole percent is based on a total number of moles of all elementsexcept lithium in the alloy composition. The alloy composition is amixture of an amorphous phase that includes silicon and ananocrystalline phase that includes tin, indium, and the sixth element.

As used herein, the terms “a”, “an”, and “the” are used interchangeablywith “at least one” to mean one or more of the elements being described.

The term “amorphous” refers to a material that lacks the long-rangeatomic order characteristic of crystalline material, as determined usingx-ray diffraction techniques.

The terms “crystalline”, “crystallite”, and “crystals” refer tomaterials that have long-range order as determined using x-raydiffraction techniques. The crystalline materials have a maximumdimension of at least about 5 nanometers. The terms “nanocrystalline”,“nanocrystallite”, and “nanocrystals” refer to a subset of crystallinematerials that have a maximum dimension of about 5 to about 50nanometers. Some crystalline materials are larger than nanocrystallinematerials (i.e., some have a maximum dimension larger than about 50nanometers).

The term “electrochemically active” refers to a material that reactswith lithium under conditions typically encountered during charging of alithium ion battery. The electrochemically active material is usually inthe form of a metal or alloy.

The term “electrochemically inactive” refers to a material that does notreact with lithium under conditions typically encountered duringcharging of a lithium ion battery.

The electrochemically inactive material is usually in the form of ametal or alloy.

The term “metal” refers to both metals and metalloids such as siliconand germanium. The metal is often in an elemental state. An“intermetallic” compound is a compound containing at least two metals.

The term “lithiation” refers to the process of adding lithium to thealloy composition (i.e., lithium ions are reduced).

The term “delithiation” refers to the process of removing lithium fromthe alloy composition (i.e., lithium atoms are oxidized).

The term “charging” refers to a process of providing electrical energyto a battery.

The term “discharging” refers to a process of removing electrical energyfrom a battery (i.e., discharging is a process of using the battery todo useful work).

The term “capacity” refers to the amount of lithium that can beincorporated into the anode material (e.g., the alloy composition) andhas units of milliamp-hours (mAh).

The term “specific capacity” refers to the capacity per unit mass of theanode material and has units of milliamp-hour/gram (mAh/g).

The term “cathode” refers to the electrode where electrochemicalreduction occurs during the discharging process. During discharging, thecathode undergoes lithiation. During charging, lithium atoms are removedfrom this electrode.

The term “anode” refers to the electrode where electrochemical oxidationoccurs during the discharging process. During discharging, the anodeundergoes delithiation. During charging, lithium atoms are added to thiselectrode.

As used herein, a “number in the range of” includes the endpoints of therange and all the numbers between the endpoints. For example, a numberin the range of 1 to 10 includes 1, 10, and all the numbers between 1and 10.

The above summary is not intended to describe each disclosed embodimentor every implementation of the present invention. The detaileddescription section that follows more particularly exemplifies theseembodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be more completely understood in consideration of thefollowing detailed description of various embodiments of the inventionin connection with the accompanying drawings, in which:

FIG. 1 is the x-ray diffraction pattern of the alloy compositionSi₆₀Al₁₄Fe₈TiInSn₆(MM)₁₀ where MM refers to mischmetal.

FIG. 2 is a plot of voltage versus capacity of an electrochemical cellhaving an electrode that contains an alloy compositionSi₆₀Al₁₄Fe₈TiInSn₆(MM)₁₀.

FIG. 3 is the x-ray diffraction pattern of the alloy compositionSi₆₀Al₁₄Fe₈TiIn₃Sn₄(MM)₁₀.

FIG. 4 is a plot of voltage versus capacity of an electrochemical cellhaving an electrode that contains an alloy compositionSi₆₀Al₁₄Fe₈TiIn₃Sn₄(MM)₁₀.

FIG. 5 is the x-ray diffraction pattern of the alloy compositionSi₅₉Al₁₆Fe₈InSn₆(MM)₁₀.

FIG. 6 is a plot of voltage versus capacity of an electrochemical cellhaving an electrode that contains an alloy compositionSi₅₉Al₁₆Fe₈InSn₆(MM)₁₀.

FIG. 7 is a plot of voltage versus capacity of an electrochemical cellhaving an electrode that contain lithium powder and an alloy compositionSi₆₀Al₁₄Fe₈TiInSn₆(MM)₁₀.

While the invention is amenable to various modifications and alternativeforms, specifics thereof have been shown by way of example in thedrawings and will be described in detail. It should be understood,however, that the intention is not to limit the invention to theparticular embodiments described. On the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention.

DETAILED DESCRIPTION

Alloy compositions are described that can be included in the anode of alithium ion battery. The alloy compositions are a mixture of anamorphous phase and a nanocrystalline phase. Compared to materials thatcontain large crystallites (i.e., crystals having a maximum dimensiongreater than about 50 nanometers), this mixture can advantageouslydecrease the risk of anode disintegration over time due to internalstress within the alloy composition. Additionally, compared to materialsthat are entirely amorphous, this mixture can advantageously result inanodes having an increased rate of lithiation. Anodes having anincreased rate of lithiation can be recharged at a faster rate.

In one aspect, lithium ion batteries are provided that include acathode, an anode, and an electrolyte that is in electricalcommunication with both the cathode and the anode. The alloy compositioncontains (a) silicon, (b) aluminum, (c) a transition metal, (d) tin, (e)indium, and (f) a sixth element that includes yttrium, a lanthanideelement, an actinide element, or a combination thereof. The amorphousphase contains silicon while the nanocrystalline phase is substantiallyfree of silicon. The nanocrystalline phase contains an intermetalliccompound that includes (1) tin, (2) indium, and (3) the sixth element.

The amorphous nature of the alloy compositions can be characterized bythe absence of sharp peaks in the x-ray diffraction pattern. The x-raydiffraction pattern can have broad peaks, such as peaks having a peakwidth at half the maximum peak height corresponding to at least 5degrees two theta, at least 10 degrees two theta, or at least 15 degreestwo theta using a copper target (i.e., copper Kα1 line, copper Kα2 line,or a combination thereof).

Nanocrystalline materials typically have a maximum dimension of about 5nanometers to about 50 nanometers. The crystalline size can bedetermined from the width of an x-ray diffraction peak using the Sherrerequation. Narrower x-ray diffraction peaks correspond to larger crystalsizes. The x-ray diffraction peaks for nanocrystalline materialstypically have a peak width at half the maximum peak heightcorresponding to less than 5 degrees two theta, less than 4 degrees twotheta, less than 3 degrees two theta, less than 2 degrees two theta, orless than 1 degree two theta using a copper target (i.e., copper Kα1line, copper Kα2 line, or a combination thereof). The nanocrystallinematerial has a peak width at half of the maximum peak heightcorresponding to at least 0.2 degrees two theta, at least 0.5 degreestwo theta, or at least 1 degree two theta using a copper target.

Because the rate of lithiation is generally greater for nanocrystallinematerial than for amorphous material, it is desirable to include somenanocrystalline material in the alloy composition. The presence ofelemental silicon in a crystalline phase, however, can result in theformation of crystalline Li₁₅Si₄ during cycling when the voltage dropsbelow about 50 mV versus a metallic Li/Li ion reference electrode. Theformation of crystalline Li₁₅Si₄ during lithiation can adversely affectthe cycle life of the anode (i.e., the capacity tends to diminish witheach cycle of lithiation and delithiation). To minimize or prevent theformation of Li₁₅Si₄ crystals, it is advantageous for silicon to bepresent in the amorphous phase and to remain in the amorphous phaseafter repetitive cycles of lithiation and delithiation. The addition ofa transition metal facilitates the formation of an amorphoussilicon-containing phase and minimizes or prevents the formation of acrystalline silicon-containing phase (e.g., crystalline elementalsilicon or crystalline silicon-containing compounds).

The nanocrystalline phase of the alloy composition includes tin, whichis another electroactive material, rather than silicon. The presence ofcrystalline elemental tin, however, can be detrimental to the capacitywhen the anode is subjected to repetitive cycles of lithiation anddelithiation. As used herein, the term “elemental” refers to an elementof the periodic table (e.g., tin, silicon, indium, or the like) that ispresent in an elemental form (i.e., as a pure element) rather thancombined with another element in the form of a compound such as anintermetallic compound.

To minimize the formation of crystalline elemental tin, an intermetalliccompound is formed that contains (1) tin, (2) indium, and (3) a sixthelement that contains yttrium, a lanthanide element, an actinideelement, or a combination thereof are added to the alloy composition.The intermetallic compound can be, for example, of formula[Sn_((1-x))In_(x)]₃M where M is an element that contains yttrium, alanthanide element, an actinide element, or a combination thereof and xis a positive number less than 1. In the absence of the indium and thesixth element, it can be difficult to control the crystalline size usingsome formation processes. For example, when an alloy is formed using amelt spinning technique without any of the sixth element or indium,relatively large crystals of elemental tin can form.

Indium tends to impede the formation of crystalline elemental tin andincreases the capacity of the alloy composition. Additionally, theaddition of indium tend to facilitate the use of melt processingtechniques such as melt spinning to form the alloy composition andincreases the likelihood that an amorphous phase will form rather than alarge crystalline phase.

The alloy composition includes an amorphous phase that includes all ofthe silicon. The amorphous phase typically includes all or a portion ofthe aluminum and all or a portion of the transition metal. The alloyfurther includes a nanocrystalline phase that includes an intermetalliccompound containing tin, indium, and the sixth element. Thenanocrystalline phase can include all or a portion of the tin, all or aportion of the indium, and all or a portion of the sixth element. Thenanocrystalline phase is substantially free of elemental tin, elementalsilicon, elemental indium, and an indium-tin binary intermetalliccompound. As used herein, the term “substantially free” when referringto the nanocrystalline phase means that the substance (e.g., elementalsilicon, elemental tin, elemental indium, or the indium-tin binaryintermetallic compound) cannot be detected using x-ray diffractiontechniques.

The specific capacity (i.e., the capacity per gram) of the alloycompositions is usually at least 200 mAh/g. In some embodiment, thespecific capacity can be at least 400 mAh/g, at least 600 mAh/g, atleast 800 mAh/g, at least 1000 mAh/g, at least 1200 mAh/g, at least, atleast 1600 mAh/g, or at least 2000 mAh/g. The specific capacity istypically measured during the discharging portion of the second cycle oflithiation and delithiation.

As used herein, the term “mole percent” when referring to constituentsof the alloy composition is calculated based on a total number of molesof all elements in the alloy composition except lithium. For example,the mole percent silicon in an alloy that contains silicon, aluminum,transition metal, tin, indium, and a sixth element is calculated bymultiplying the moles of silicon by 100 and dividing this product by thetotal moles of all elements except lithium in the alloy composition(e.g., moles of silicon+moles of aluminum+moles of transitionmetal+moles of tin+mole of indium+moles of sixth element).

All of the silicon is generally in the amorphous phase. Silicon ispresent in the alloy composition in an amount of 35 to 70 mole percentbased on the total number of moles of all elements except lithium in thealloy composition. If the amount of silicon is too low, the capacity canbe unacceptably low. If the amount of silicon is too high, however,silicon-containing crystals tend to form. The presence of crystallinesilicon, at least in some embodiments, can lead to the formation ofLi₁₅Si₄ during cycling when the voltage drops below about 50 mV versus ametallic Li/Li ion reference electrode. Crystalline Li₁₅Si₄ candetrimentally affect the cycle life of a lithium ion battery.

The alloy composition contains at least 35 mole percent, at least 45mole percent, at least 50 mole percent, at least 55 mole percent, or atleast 60 mole percent silicon. The alloy composition can contain up to70 mole percent, up to 65 mole percent, or up to 60 mole percentsilicon. For example, the alloy composition can contain 40 to 70 molepercent, 50 to 70 mole percent, 55 to 70 mole percent, or 55 to 65 molepercent silicon.

Aluminum is another element that is present in the alloy composition.The aluminum is typically present in the amorphous phase and, along withthe transition metal, facilitates the formation of the amorphous phasethat contains all of the silicon. The aluminum can be electrochemicallyactive, electrochemically inactive, or a combination thereof. If thealuminum is present as elemental aluminum, it is often electrochemicallyactive. Electrochemically active aluminum can enhance the capacity ofthe alloy composition. If the aluminum is present as an intermetalliccompound with a transition metal, however, it can be electrochemicallyinactive. As an electrochemically inactive material, an aluminumintermetallic compound can function as a matrix for theelectrochemically active components.

Aluminum is present in the alloy composition in an amount of 1 to 45mole percent based on the total number of moles of all elements exceptlithium in the alloy composition. The addition of aluminum to the alloycomposition often lowers the melting point, which can facilitate the useof various melt processing technique such as melt spinning to form thealloy composition. Melt processing techniques are often less expensivethan techniques such as sputtering. If the aluminum level is too low, itcan be more difficult to form an amorphous phase that contains all ofthe silicon. Too much aluminum, however, can detrimentally affect thecycle life of the lithium ion battery. That is, too much aluminum canresult in an unacceptably large capacity decrease when the anode issubjected to repetitive cycles of lithiation and delithiation.

The alloy composition contains up to 45 mole percent, up to 40 molepercent, up to 35 mole percent, up to 30 mole percent, up to 25 molepercent, up to 20 mole percent, or up to 15 mole percent aluminum. Thealuminum in the alloy composition is often present in an amount of atleast 1 mole percent, at least 2 mole percent, at least 5 mole percent,or at least 10 mole percent. For example, the alloy composition cancontain 2 to 40 mole percent, 3 to 40 mole percent, 5 to 40 molepercent, 10 to 40 mole percent, 10 to 30 mole percent, or 10 to 20 molepercent aluminum.

The alloy composition also includes a transition metal in an amount of 5to 25 mole percent based on the total number of moles of all elementsexcept lithium in the alloy composition. Suitable transition metalsinclude, but are not limited to, titanium, vanadium, chromium,manganese, iron, cobalt, nickel, copper, zirconium, niobium, molybdenum,tungsten, and combinations thereof. The transition metal, in combinationwith aluminum, facilitates the formation of the amorphous phase. If toolittle transition metal is included in the alloy composition, it can bemore difficult to form an amorphous phase that includes all of thesilicon. If the transition metal concentration is too high, however, thecapacity of the alloy composition can be unacceptably low because thetransition metal is electrochemically inactive or combines with othercomponents such as aluminum to form an intermetallic compound that iselectrochemically inactive.

The transition element is present in an amount of at least 5 molepercent, at least 8 mole percent, at least 10 mole percent, or at least12 mole percent. The alloy composition contains up to 25 mole percent,up to 20 mole percent, or up to 15 mole percent transition metal. Forexample, the alloy composition includes 5 to 20 mole percent, 5 to 15mole percent, 8 to 25 mole percent, 8 to 20 mole percent, or 10 to 25mole percent transition metal.

Tin is yet another element present in the alloy composition. Tin istypically present in the nanocrystalline phase as an intermetalliccompound with (1) indium and (2) a sixth metal that contains yttrium, alanthanide element, an actinide element, or a combination thereof. Thenanocrystalline material is often of formula [Sn_((1-x))In_(x)]₃M whereM is an element that contains yttrium, a lanthanide element, an actinideelement, or a combination thereof and x is a positive number lessthan 1. Depending on the relative ratios of tin, indium, and the sixthelement, multiple nanocrystalline materials can be present in the alloycomposition. For example, the nanocrystalline material can include Sn₃M,In₃M, or both in addition to [Sn_((1-x))In_(x)]₃M.

The nanocrystalline phase can increase the rate of lithiation of thealloy composition, particularly during the first cycle of lithiation anddelithiation. Although not wanting to be bound by theory, thenanocrystalline phase may be analogous to veins through the amorphousphase. The nanocrystalline phase may provide a conduction path forlithium throughout the alloy composition, which may allow lithium todiffuse quickly along the grain boundaries between the nanocrystallinephase and the amorphous phase.

The alloy composition contains 1 to 15 mole percent tin based on thetotal number of moles of all elements except lithium in the alloycomposition. If too much tin is present, crystalline tin can form ratherthan a nanocrystalline tin-containing, intermetallic compound.Crystalline elemental tin detrimentally affects the capacity when theanode is subjected to repetitive cycles of lithiation and delithiation.That is, too much tin can cause the capacity to decrease unacceptablywhen the anode is subjected to repetitive cycles of lithiation anddelithiation. If the amount of tin is too low, however, the rate oflithiation may be comparable to that of an amorphous material.

Tin is present in an amount up to 15 mole percent, up to 12 molepercent, up to 10 mole percent, up to 9 mole percent, up to 8 molepercent, up to 7 mole percent, up to 6 mole percent, or up to 5 molepercent. Tin is usually present in an amount of at least 1 mole percent,at least 2 mole percent, at least 3 mole percent, at least 4 molepercent, or at least 5 mole percent. For example, the alloy compositioncan contain 1 to 12 mole percent, 1 to 10 mole percent, 1 to 9 molepercent, 2 to 9 mole percent, 2 to 8 mole percent, or 3 to 9 molepercent tin.

Indium is present in the alloy composition in an amount up to 15 molepercent based on the total number of all elements except lithium in thealloy composition. Indium is part of the nanocrystalline phase in theform of an intermetallic compound that also includes tin and the sixthelement. The alloy composition is typically substantially free ofcrystalline elemental indium. The alloy composition is typicallysubstantially free of crystalline binary indium-tin intermetalliccompounds such as Sn_((1-y))In_(y) where y is a number less than 1 suchas, for example, Sn_(0.8)In_(0.2).

The presence of indium in the nanocrystalline intermetallic compoundtypically improves cycle life of the alloy composition. Morespecifically, indium improves the retention of the capacity afterrepeated cycles of lithiation and delithiation. If too much indium ispresent, crystalline elemental indium can form rather than ananocrystalline intermetallic compound with tin and the sixth element.Crystalline elemental indium can disadvantageously lead to a decreasedcapacity when the anode is subjected to repetitive cycles of lithiationand delithiation.

The alloy composition often contains at least 0.1 mole percent, at least0.2 mole percent, at least 0.5 mole percent, or at least 1 mole percentindium. The amount of indium in the alloy composition is often up to 15mole percent, up to 12 mole percent, up to 10 mole percent, up to 8 molepercent, or up to 6 mole percent. For example, the alloy composition cancontain 0.1 to 15 mole percent, 0.1 to 10 mole percent, 0.2 to 10 molepercent, 0.5 to 10 mole percent, 1 to 10 mole percent, or 2 to 10 molepercent indium.

A sixth element is included in the alloy composition that containsyttrium, a lanthanide element, an actinide element, or a combinationthereof in an amount of 2 to 15 mole percent based on the total numberof moles all elements except lithium in the alloy composition. The sixthelement is included in the nanocrystalline phase and combines with tinand indium to form an intermetallic compound. If the alloy compositioncontains too much of the sixth element, the capacity can be reducedbecause the sixth element is typically electrochemically inactive. Onthe other hand, if the amount of the sixth element is too low, there canbe some tin that is in the form of crystalline elemental tin rather thanin the form of an intermetallic compound. The presence of crystallineelemental tin can deleteriously affect the capacity when the lithium ionbattery is subjected to repetitive cycles of lithiation anddelithiation. The nanocrystalline phase is substantially free of astoichiometric compound such as a silicide formed by combining siliconwith the sixth element. A stoichiometric compound has a defined ratiobetween the elements in the compound with the ratio being a rationalnumber.

Suitable lanthanide elements include lanthanum, cerium, praseodymium,neodymium, promethium, samarium, europium, gadolinium, terbium,dysprosium, holmium, erbium, thulium, ytterbium, and lutetium. Suitableactinide elements include thorium, actinium, and protactinium. Somealloy compositions contain a lanthanide elements selected, for example,from cerium, lanthanum, praseodymium, neodymium, or a combinationthereof.

The sixth element can be a mischmetal, which is an alloy of variouslanthanides. Some mischmetals contains, for example, 45 to 60 weightpercent cerium, 20 to 45 weight percent lanthanum, 1 to 10 weightpercent praseodymium, and 1 to 25 weight percent neodymium. Othermischmetals contains 30 to 40 weight percent lanthanum, 60 to 70 weightpercent cerium, less than 1 weight percent praseodymium, and less than 1weight percent neodymium. Still other mischmetal contains 40 to 60weight percent cerium and 40 to 60 weight percent lanthanum. Themischmetals often includes small impurities (e.g., less than 1 weightpercent, less than 0.5 weight percent, or less than 0.1 weight percent)such as, for example, iron, magnesium, silicon, molybdenum, zinc,calcium, copper, chromium, lead, titanium, manganese, carbon, sulfur,and phosphorous. The mischmetal often has a lanthanide content of atleast 97 weight percent, at least 98 weight percent, or at least 99weight percent. One exemplary mischmetal that is commercially availablefrom Alfa Aesar, Ward Hill, Mass. with 99.9 weight percent puritycontains approximately 50 weight percent cerium, 18 weight percentneodymium, 6 weight percent praseodymium, 22 weight percent lanthanum,and 3 weight percent other rare earths.

The alloy composition contains at least 2 mole percent, at least 3 molepercent, or at least 5 mole percent of the sixth element. The sixthelement can be present in amounts up to 15 mole percent, up to 12 molepercent, or up to 10 mole percent in the alloy composition. For example,the alloy composition can contain 3 to 15 mole percent, 5 to 15 molepercent, 3 to 12 mole percent, or 3 to 10 mole percent of the sixthelement. In some embodiments, the sixth element is a lanthanide elementor a mixture of lanthanide elements.

The alloy composition is substantially free of an alkaline earth metalsuch as calcium, barium, magnesium, and the like. As used herein, theterm “substantially free” with reference to an alkaline earth metalmeans that the alloy composition contains no more than 1 mole percentalkaline earth, no more than 0.5 mole percent alkaline earth, no morethan 0.2 mole percent alkaline earth, or no more than 0.1 mole percentalkaline earth. An alkaline earth, if present in the alloy composition,is typically present as an impurity of another component and is notpurposefully added.

The alloy composition can further include an alkali metal such aslithium. Prior to the first lithiation reaction, the alloy compositiontypically contains little or no lithium. After the first lithiation, theamount of lithium can vary but is typically greater than zero even afterthe lithium ion battery has been discharged. That is, the anodecontaining the alloy composition often has at least a small amount ofirreversible capacity.

The alloy compositions are often of Formula I:Si_(a)Al_(b)T_(c)Sn_(d)In_(e)M_(f)Li_(g)  (I)where a is a number in the range of 35 to 70; b is a number in the rangeof 1 to 45; T is a transition metal; c is a number in the range of 5 to25; d is a number in the range of 1 to 15; e is a number up to 15; M isyttrium, a lanthanide element, or a combination thereof; f is a numberin the range of in the range of 2 to 15; and the sum of a+b+c+d+e+f isequal to 100. The variable g is a number in the range of 0 to[4.4(a+d+e)+b].

In some exemplary compositions according to Formula I, the variable a isa number in the range of 40 to 65; b is a number in the range of 1 to25; c is a number in the range of 5 to 25; d is a number in the range of1 to 15; e is a number up to 15; and f is a number in the range of 2 to15. In other exemplary compositions according to Formula I, the variablea is a number in the range of 40 to 55; b is a number in the range of 25to 45; c is a number in the range of in the range of 5 to 25; d is anumber in the range of 1 to 15; e is a number up to 15; and f is anumber in the range of 2 to 15. In still other exemplary compositions,the variable a is a number in the range of 55 to 65; b is a number inthe range of 10 to 20; c is a number in the range of 5 to 25; d is anumber in the range of 1 to 15; e is a number up to 15; and f is anumber in the range of 2 to 15.

The alloy composition of the anode can be in the form of a thin film orpowder, the form depending on the technique chosen to prepare thematerials. Suitable methods of preparing the alloy compositions include,but are not limited to, sputtering, chemical vapor deposition, vacuumevaporation, melt processing such as melt spinning, splat cooling, sprayatomization, electrochemical deposition, and ball milling.

The method of making the alloy composition often involves forming anamorphous precursor material and then annealing the precursor materialat a temperature in the range of about 150° C. to about 400° C.Annealing tends to convert the precursor material that is entirelyamorphous into an alloy composition that is a mixture of an amorphousphase and a nanocrystalline phase. The annealing step is typicallyconducted by heating the precursor material in an inert environment suchas argon or helium.

Sputtering is a procedure for producing amorphous precursor. Thedifferent elements can be sputtered simultaneously or sequentially. Forexample, the elements can be sequentially sputter-coated on a substratesuch as a copper substrate. The substrates can be positioned near theedge of a turntable (e.g., 25 inch diameter) that rotates continuouslybelow multiple sputtering sources that are operating continuously. Alayer of one material can be deposited as the substrate passes under thefirst sputtering source, and additional layers of different material canbe deposited as the substrate passes under the other sputtering sources.The amount of material deposited from each sputtering source can becontrolled by varying the rotation speed of the turntable and by varyingthe sputtering rates. Suitable sputtering methods are further describedin U.S. Pat. No. 6,203,944 B1 (Turner et al.); U.S. Pat. No. 6,436,578B1 (Turner et al.); and U.S. Pat. No. 6,699,336 B2 (Turner et al.), allof which are incorporated herein by reference.

Melt processing is another procedure that can be used to produceprecursors or for producing alloy compositions that are a mixture ofamorphous materials and nanocrystalline materials. Such processes aredescribed generally, for example, in Amorphous Metallic Alloys, F. E.Luborsky, ed., Chapter 2, Butterworth & Co., Ltd., 1983. Ingotscontaining the reactants can be melted in a radio frequency field andthen ejected through a nozzle onto a surface of a rotating wheel (e.g.,a copper alloy wheel) that can be cooled. Because the surfacetemperature of the rotating wheel is substantially lower than thetemperature of the melt, contact with the surface of the rotating wheelquenches the melt. Rapid quenching minimizes the formation ofcrystalline material and favors the formation of amorphous materials.Suitable melt processing methods are further described in U.S. Pat. No.6,699,336 B2 (Turner et al.), incorporated herein by reference. Themelt-processed material can be in the form, for example, of a ribbon ora thin film.

In some melt processing procedures, depending on the quenching rate andthe particular material, the resulting material can be a mixture of anamorphous phase and a single nanocrystalline phase that includes anintermetallic compound of tin, indium, and the sixth element. In othermelt processing procedures, however, the melt-processed material is aprecursor that contains (1) an amorphous phase, (2) a ternarynanocrystalline phase that includes an intermetallic compound of tin,indium and the sixth element, and (3) a crystalline (e.g.,nanocrystalline) elemental tin phase, a crystalline indium phase, acrystalline binary tin-indium phase of formula Sn_((1-y))In_(y) where yis a positive number less than 1 such as, for example, Sn_(0.8)In_(0.2),or a combination thereof. The crystalline elemental tin phase,crystalline indium phase, and the crystalline binary tin-indium phasecan often be removed by annealing the melt-processed precursor materialat a temperature in the range of about 150° C. to about 400° C. under aninert atmosphere. In still other melt processing methods, themelt-processed material is a precursor that contains only amorphousmaterials. The precursor can be annealed at a temperature in the rangeof about 150° C. to about 400° C. under an inert atmosphere to preparethe alloy composition that contains both an amorphous phase and ananocrystalline phase.

The sputtered or melt processed alloy compositions can be furthertreated to produce powdered materials. For example, a ribbon or thinfilm of the alloy composition can be pulverized to form a powder. Thepowder can be formed before or after any annealing step. Exemplarypowders have a maximum dimension that is no greater than 60 micrometers,no greater than 40 micrometers, or no greater than 20 micrometers. Thepowders often have a maximum dimension of at least 1 micrometer, atleast 2 micrometers, at least 5 micrometers, or at least 10 micrometers.For example, suitable powders often have a maximum dimension of 1 to 60micrometers, 10 to 60 micrometers, 20 to 60 micrometers, 40 to 60micrometers, 1 to 40 micrometers, 2 to 40 micrometers, 10 to 40micrometers, 5 to 20 micrometers, or 10 to 20 micrometers.

In some embodiments, the anode contains the alloy composition dispersedin an elastomeric polymer binder. Exemplary elastomeric polymer bindersinclude polyolefins such as those prepared from ethylene, propylene, orbutylene monomers; fluorinated polyolefins such as those prepared fromvinylidene fluoride monomers; perfluorinated polyolefins such as thoseprepared from hexafluoropropylene monomer; perfluorinated poly(alkylvinyl ethers); perfluorinated poly(alkoxy vinyl ethers); or combinationsthereof. Specific examples of elastomeric polymer binders includeterpolymers of vinylidene fluoride, tetrafluoroethylene, and propylene;and copolymers of vinylidene fluoride and hexafluoropropylene.Commercially available fluorinated elastomers include those sold byDyneon, LLC, Oakdale, Minn. under the trade designation “FC-2178”,“FC-2179”, and “BRE-7131X”.

In some anodes, the elastomeric binders are crosslinked. Crosslinkingcan improve the mechanical properties of the polymer and can improve thecontact between the alloy composition and any electrically conductivediluent that may be present.

In other anodes, the binder is a polyimide such as the aliphatic orcycloaliphatic polyimides described in U.S. Patent Publication No.2006/0099506 (Krause et al.). Such polyimide binders have repeatingunits of Formula II

where R¹ is aliphatic or cycloaliphatic; and R² is aromatic, aliphatic,or cycloaliphatic.

The aliphatic or cycloaliphatic polyimide binders may be formed, forexample, using a condensation reaction between an aliphatic orcycloaliphatic polyanhydride (e.g., a dianhydride) and an aromatic,aliphatic or cycloaliphatic polyamine (e.g., a diamine or triamine) toform a polyamic acid, followed by chemical or thermal cyclization toform the polyimide. The polyimide binders may also be formed usingreaction mixtures additionally containing aromatic polyanhydrides (e.g.,aromatic dianhydrides), or from reaction mixtures containing copolymersderived from aromatic polyanhydrides (e.g., aromatic dianhydrides) andaliphatic or cycloaliphatic polyanhydrides (e.g., aliphatic orcycloaliphatic dianhydrides). For example, about 10 to about 90 percentof the imide groups in the polyimide may be bonded to aliphatic orcycloaliphatic moieties and about 90 to about 10 percent of the imidegroups may be bonded to aromatic moieties. Representative aromaticpolyanhydrides are described, for example, in U.S. Pat. No. 5,504,128(Mizutani et al.).

An electrically conductive diluent can be mixed with the alloycomposition in the anode. Exemplary electrically conductive diluentsinclude, but are not limited to, carbon, metal, metal nitrides, metalcarbides, metal silicides, and metal borides. In some anodes, theelectrically conductive diluents are carbon blacks such as thosecommercially available from MMM Carbon of Belgium under the tradedesignation “SUPER P” and “SUPER S” or from Chevron Chemical Co. ofHouston, Tex. under the trade designation “SHAWINIGAN BLACK”; acetyleneblack; furnace black; lamp black; graphite; carbon fibers; orcombinations thereof.

The anode can further include an adhesion promoter that promotesadhesion of the alloy composition and the electrically conductivediluent to the elastomeric polymer binder. The combination of anadhesion promoter and elastomeric polymer binder accommodates, at leastpartially, volume changes that may occur in the alloy composition duringrepeated cycles of lithiation and delithiation. The adhesion promotercan be part of the binder (e.g., in the form of a functional group) orcan be in the form a coating on the alloy composition, the electricallyconductive diluent, or a combination thereof. Examples of adhesionpromoters include, but are not limited to, silanes, titanates, andphosphonates as described in U.S. Pat. No. 7,341,804, the disclosure ofwhich is incorporated herein by reference.

The anode can be partially lithiated prior to or during the batteryassembly process. Adding lithium to the anode can increase the energydelivered by the battery during discharging. In some embodiments, theanode is partially lithiated by dispersing a lithium powder, the alloycomposition, and a conductive diluent in a solution of a polymer binder.The dispersion can be coated, dried to remove any solvent, and cured toform the electrode. In other embodiments, lithium foil or a lithiummetal powder can be added to the surface of a previously curedelectrode. In the case of a lithium metal powder, the powder can bedistributed 1) by sprinkling the powder directly onto the surface of theelectrode or 2) by dispersing the lithium metal powder in a volatilesolvent that is non-reactive, followed by evenly coating the lithiumdispersion onto the electrode surface and evaporating off the solvent.The lithium foil or lithium metal powder can then be affixed to theelectrode by a calendaring process. Although anodes that contain lithiumcan be heated before battery assembly to react the lithium with theother components of the anode, such anodes are typically assembled intobatteries without heating. During the battery assembly process, thelithium can react with the other components of the anode coating whenelectrolyte is added.

Any suitable electrolyte can be included in the lithium ion battery. Theelectrolyte can be in the form of a solid or liquid. Exemplary solidelectrolytes include polymeric electrolytes such as polyethylene oxide,polytetrafluoroethylene, polyvinylidene fluoride, fluorine-containingcopolymers, polyacrylonitrile, or combinations thereof. Exemplary liquidelectrolytes include ethylene carbonate, fluoroethylene carbonate,dimethyl carbonate, diethyl carbonate, propylene carbonate,gamma-butyrolactone, tetrahydrofuran, 1,2-dimethoxyethane, dioxolane,4-fluoro-1,3-dioxalan-2-one, or combinations thereof. The electrolyteincludes a lithium electrolyte salt such as LiPF₆, LiBF₄, LiClO₄,LiN(SO₂CF₃)₂, LiN(SO₂CF₂CF₃)₂, and the like.

The electrolyte can include a redox shuttle molecule, anelectrochemically reversible material that during charging can becomeoxidized at the cathode, migrate to the anode where it can becomereduced to reform the unoxidized (or less-oxidized) shuttle species, andmigrate back to the cathode. Exemplary redox shuttle molecules includethose described in U.S. Pat. Nos. 5,709,968 (Shimizu), 5,763,119(Adachi), 5,536,599 (Alamgir et al.), 5,858,573 (Abraham et al.),5,882,812 (Visco et al.), 6,004,698 (Richardson et al.), 6,045,952 (Kerret al.), and 6,387,571 B1 (Lain et al.); in PCT Published PatentApplication No. WO 01/29920 A1 (Richardson et al.); and in U.S. Pat.Nos. 7,615,312 (Dahn et al.), 7,615,317 (Dahn et al.), 7,585,590 Wang etal.); and U.S. Patent Application Publication No. 2005-0221196A1.

Any suitable cathode known for use in lithium ion batteries can beutilized. Some exemplary cathodes include lithium transition metal oxidesuch as lithium cobalt dioxide, lithium nickel dioxide, and lithiummanganese dioxide. Other exemplary cathodes are disclosed in U.S. Pat.No. 6,680,145 B2 (Obrovac et al.), incorporated herein by reference, andinclude transition metal grains in combination with lithium-containinggrains. Suitable transition metal grains include, for example, iron,cobalt, chromium, nickel, vanadium, manganese, copper, zinc, zirconium,molybdenum, niobium, or combinations thereof with a grain size nogreater than about 50 nanometers. Suitable lithium-containing grains canbe selected from lithium oxides, lithium sulfides, lithium halides(e.g., chlorides, bromides, iodides, or fluorides), or combinationsthereof. These particles can be used alone or in combination with alithium-transition metal oxide material such as lithium cobalt dioxide.

In some lithium ion batteries with solid electrolytes, the cathode caninclude LiV₃O₈ or LiV₂O₅. In other lithium ion batteries with liquidelectrolytes, the cathode can include LiCoO₂, LiCo_(0.2)Ni_(0.8)O₂,LiMn₂O₄, LiFePO₄, or LiNiO₂.

The lithium ion batteries can be used as a power supply in a variety ofapplications. For example, the lithium ion batteries can be used inpower supplies for electronic devices such as computers and varioushand-held devices, motor vehicles, power tools, photographic equipment,and telecommunication devices. Multiple lithium ion batteries can becombined to provide a battery pack.

EXAMPLES

Aluminum, silicon, iron, titanium, zirconium, tin, and cobalt wereobtained from Alfa Aesar, Ward Hill, Mass. or Aldrich, Milwaukee, Wis.Indium was obtained from Indium Corporation of America, Utica, N.Y.These materials had a purity of at least 99.8 weight percent. A mixtureof rare earth elements, also known as mischmetal (MM), was also obtainedfrom Alfa Aesar with 99.0 weight percent minimum rare earth contentwhich contained approximately 50 weight percent cerium, 18 weightpercent neodymium, 6 weight percent praseodymium, 22 weight percentlanthanum, and 4 weight percent other rare earth elements.

The alloy compositions were formed into electrodes and characterized inelectrochemical cells using a lithium metal counter electrode.

Example 1 Si₆₀Al₁₄Fe₈TiInSn₆(MM)₁₀

An alloy composition Si₆₀Al₁₄Fe₈TiInSn₆(MM)₁₀ was prepared by mixing17.606 g of silicon chips, 3.947 g of aluminum shot, 4.668 g of ironlumps, 0.500 g titanium sponge, 7.441 g tin shot, 1.200 g indium, and14.639 g of mischmetal chunks. The mixture was melted together on acarbon hearth in an argon filled arc furnace purchased from AdvancedVacuum Systems, Ayer, Mass. The resulting ingot had a composition ofSi₆₀Al₁₄Fe₈TiSn₆InMm and was broken into pieces having dimensions ofabout 1 cm in all directions.

The ingots were then further processed by melt spinning in amelt-spinning apparatus that included a vacuum chamber having acylindrical quartz glass crucible (16 mm internal diameter and 140 mmlength) with a 0.35 mm orifice that was positioned above a rotatingcooling wheel. The rotating cooling wheel (10 mm thick and 203 mmdiameter) was fabricated from a copper alloy (Ni—Si—Cr—Cu C18000 alloy,0.45 weight percent chromium, 2.4 weight percent nickel, 0.6 weightpercent silicon with the balance being copper) that is commerciallyavailable from Nonferrous Products, Inc. from Franklin, Ind. Prior toprocessing, the edge surface of the cooling wheel was polished using arubbing compound (commercially available from 3M, St. Paul, Minn. underthe trade designation IMPERIAL MICROFINISHING) and then wiped withmineral oil to leave a thin film.

After placing 15 g of the ingot in the crucible, the melt spinningapparatus was evacuated to 80 mT (milliTorr) and then filled with heliumgas to 200 T. The ingot was melted using radio frequency induction. Asthe temperature reached 1300° C., 400 T helium pressure was applied tothe surface of the molten material and a sample was extruded through anozzle onto the spinning (5031 revolutions per minute) cooling wheel.Ribbon strips were formed that had a width of 1 mm and a thickness of 10micrometers.

FIG. 1 shows the x-ray diffraction (XRD) pattern of the resultingmelt-spun ribbon sample taken with a Siemens D500 x-ray diffractometerequipped with a copper target (Kα1, Kα2 lines). The XRD pattern showsthat the alloy contained an amorphous phase and a nanocrystalline phase.The broad hump is indicative of amorphous material and the individualpeaks are of a width indicative of nanocrystalline material The XRDpattern lacks sharp peaks associated with elemental silicon, elementaltin, elemental indium, or a binary intermetallic compound of tin andindium.

The following components were added to a 40 ml tungsten carbide millingvessel containing two 10 mm diameter and ten 3 mm diameter tungstencarbide balls: 1.6 g of the above ribbon, 240 mg of carbon black(commercially available from MMM Carbon, Belgium under the tradedesignation SUPER P), 0.8 g of a polyimide coating solution(commercially available from HD Microsystems, Cheesequake Rd, Parlin,N.J. under the trade designation PYRALIN P12555 as a 20 weight percentsolution in N-methyl-2-pyrrolidinone), and 4.2 g of N-methyl-2-pyrroline(commercially available from Aldrich, Milwaukee, Wis.). The millingvessel was placed in a planetary mill (PULVERISETTE 7, available fromFritsch GmbH, Idon-Oberstein, Germany) and the contents were milled at asetting of “3” for 1 hour.

After milling, the mixture was transferred to a notched coating bar andcoated onto a 15 micrometer thick copper foil as a strip having a widthof 25 mm and a thickness of 125 micrometers. The strips were cured at150° C. under vacuum conditions for 2.5 hours to form an electrode. Theelectrode was then used to construct 2325 coin cells having a 300micrometer thick metallic lithium foil counter/reference electrode, twolayers of a flat sheet polypropylene membrane separator (CELGARD 2400,commercially available from CELGARD Inc., Charlotte, N.C.), and 1 MLiPF₆ in a 1:2 mixture of ethylene carbonate and diethyl carbonate asthe electrolyte. The 2325 coin cell hardware is described in A. M.Wilson and J. R. Dahn, J. Electrochem. Soc., 142, 326-332 (1995).

Electrochemical cells were cycled between 0.9 V vs. the metallic Li/Liion reference electrode and 5 mV vs. the metallic Li/Li ion referenceelectrode at a constant current of 100 mA/g (500 μA) using a cell tester(Maccor Inc., Tulsa Okla.). The current was allowed to relax to 10 mA/g(50 μA) at the lower voltage cutoff before the next charge cycle. Thevoltage versus capacity curve is shown in FIG. 2. The reversiblespecific capacity was 900 mAh/g.

Example 2 Si₆₀Al₁₄Fe₈TiIn₃Sn₄(MM)₁₀

An alloy composition Si₆₀Al₁₄Fe₈TiIn₃Sn₄(MM)₁₀ was prepared using aprocedure similar to Example 1 by mixing 17.634 g of silicon chips,3.953 g of aluminum shot, 4.675 g of iron lumps, 0.501 g titaniumsponge, 4.969 g tin shot, 3.605 g indium, and 14.663 g of mischmetal.The resulting melt-spun ribbon was annealed by heating at 200° C. for 2hours under flowing argon. FIG. 3 shows the XRD pattern.

The resulting alloy composition was tested in electrochemical cells asdescribed in Example 1. An electrochemical cell was prepared using theprocedure described in Example 1. The voltage versus capacity curve ofthis material is shown in FIG. 4. The reversible specific capacity was950 mAh/g.

Example 3 Si₅₉Al₁₆Fe₈In₁Sn₆(MM)₁₀

An alloy composition Si₅₉Al₁₆Fe₈In₁Sn₆(MM)₁₀ was prepared using aprocedure similar to Example 1 by mixing 9.062 g aluminum, 34.785 gsilicon, 9.379 g iron, 2.410 g indium, 14.949 g tin, and 29.414 gmischmetal. The melt spinning was at 1350° C.

10 g of the melt-spun ribbon was annealed for 2 hrs at 200° C. in a tubefurnace under a flow of argon. The XRD pattern of the resulting alloycomposition is shown in FIG. 5.

The following components were added to a 40 ml tungsten carbide millingvessel containing two 10 mm diameter carbide balls and ten 3 mm diametertungsten carbide balls: 1.70 g of the above melt-spun ribbon, 100 mg ofSUPER P carbon (available from MMM Carbon, Belgium), 1.0 g of apolyimide coating solution (commercially available from HD Microsystems,Cheesequake Rd, Parlin, N.J. under the trade designation PYRALIN PI2555as a 20 weight percent solution in N-methyl-2-pyrrolidinone), and 5.2 gof N-methyl-2-pyrrolidinone (commercially available from Aldrich,Milwaukee, Wis.). The milling vessel was placed in a planetary mill(PULVERISETTE 7, commercially available from Fritsch GmbH,Idon-Oberstein, Germany) and the contents were milled at a setting of“4” for one hour.

After milling the solution was transferred to a notch coating bar andcoated onto a copper foil having a thickness 15 micrometers. The coatedstrip had a width of 25 mm and a thickness of 125 micrometers. Thecoating was cured at 150° C. under a vacuum for 2.5 hours.Electrochemical cells were prepared as described in Example 1. Thevoltage versus capacity curve is shown in FIG. 6. The reversiblespecific capacity was 750 mAh/g.

Example 4

Lithium metal powder was made by chopping 150 micrometer thick lithiumfoil repeatedly with a razor blade until the maximum dimension of theindividual particles were about 150 micrometers. 0.80 mg of the lithiumpowder was sprinkled onto a piece cut from the cured electrode describedin Example 1 containing 5.84 mg of Si₆₀Al₁₄Fe₈TiInSn₆(MM)₁₀. Theelectrode was then placed in-between two pieces of polyethylene film andcalendared by means of a hand roller. The resulting electrode wasassembled into an electrochemical cell versus a lithium counterelectrode as described in Example 1. The cell was cycled between 0.9 Vvs. a metallic Li/Li⁺ reference electrode and 5 mV vs. Li metal Li/Liion reference electrode at a constant current of 100 mA/g using a celltester (Maccor Inc., Tulsa Okla.). The voltage versus capacity curve isshown in FIG. 7. The reversible specific capacity was 650 mAh/g.

1. A lithium ion battery comprising a cathode, an anode, and anelectrolyte in electrical communication with both the anode and thecathode, wherein the anode comprises an alloy composition comprising a)silicon in an amount of 35 to 70 mole percent; b) aluminum in an amountof 1 to 45 mole percent; c) a transition metal in an amount of 5 to 25mole percent; d) tin in an amount of 1 to 15 mole percent; e) indium inan amount up to 15 mole percent; and f) a sixth element comprisingyttrium, a lanthanide element, an actinide element, or a combinationthereof in an amount of 2 to 15 mole percent, wherein each mole percentis based on a total number of moles of all elements except lithium inthe alloy composition; wherein the alloy composition is a mixture of anamorphous phase comprising silicon and a nanocrystalline phasecomprising an intermetallic compound with tin, indium, and the sixthelement, and wherein the nanocrystalline phase comprises crystallinematerials having a maximum dimension of about 5 to about 50 nanometers.2. The lithium ion battery of claim 1, wherein the amorphous phasefurther comprises aluminum and the transition metal.
 3. The lithium ionbattery of claim 1, wherein the sixth element comprises cerium,lanthanum, praseodymium, neodymium, or a combination thereof.
 4. Thelithium ion battery of claim 1, wherein the nanocrystalline phase issubstantially free of silicon.
 5. The lithium ion battery of claim 1,wherein the nanocrystalline phase is substantially free of elementaltin, elemental indium, a binary tin-indium compound, or a combinationthereof.
 6. The lithium ion battery of claim 1, wherein the alloycomposition further comprises less than 1 mole percent alkaline earthmetal.
 7. The lithium ion battery of claim 1, wherein the alloycomposition further comprises an alkaline metal.
 8. The lithium ionbattery of claim 1, wherein the alloy composition comprises particleshaving a maximum average dimension of 1 to 60 micrometers.
 9. Thelithium ion battery of claim 1, wherein the alloy composition has asingle amorphous phase and a single nanocrystalline phase.
 10. Thelithium ion battery of claim 1, wherein the alloy composition is ofFormula ISi_(a)Al_(b)T_(c)Sn_(d)In_(e)M_(f)Li_(g)  (I) wherein a is a in therange of 35 to 70; b is a number in the range of 1 to 45; T is atransition metal; c is a number in the range of 5 to 25; d is a numberin the range of 1 to 15; e is a number up to 15; M is yttrium, alanthanide element, an actinide element, or a combination thereof; f isa number in the range of 2 to 15; the sum of a+b+c+d+e+f is equal to100; and g is a number in the range of 0 to [4.4(a+d+e)+b].
 11. Thelithium ion battery of claim 10, wherein the variable a is a number inthe range of 40 to 65; b is a number in the range of 1 to 25; c is anumber in the range of 5 to 25; d is a number in the range of 1 to 15; eis a number up to 15; and f is a number in the range of 2 to
 15. 12. Thelithium ion battery of claim 10, wherein the variable a is a number inthe range of 40 to 55; b is a number in the range of 25 to 45; c is anumber in the range of 5 to 25; d is a number in the range of 1 to 15; eis a number up to 15; and f is a number in the range of 2 to
 15. 13. Thelithium ion battery of claim 10, wherein the variable a is a number inthe range of 55 to 65; b is a number in the range of 10 to 20; c is anumber in the range of 5 to 25; d is a number in the range of 1 to 15; eis a number up to 15; and f is a number in the range of 2 to
 15. 14. Thelithium ion battery of claim 10, wherein the anode further comprises anorganic binder comprising a polyimide.
 15. The lithium ion battery ofclaim 1, wherein the anode further comprises lithium metal.
 16. Abattery pack comprising at least one lithium ion battery according toclaim
 1. 17. A method of preparing a lithium ion battery, said methodcomprising: providing an anode comprising an alloy compositioncomprising a) silicon in an amount of 35 to 70 mole percent; b) aluminumin an amount of 1 to 45 mole percent; c) a transition metal in an amountof 5 to 25 mole percent; d) tin in an amount of 1 to 15 mole percent; e)indium in an amount up to 15 mole percent; and f) yttrium, a lanthanideelement, an actinide element, or a combination thereof in an amount of 2to 15 mole percent, wherein each mole percent is based on a total numberof moles of all elements except lithium in the alloy composition andwherein the alloy composition is a mixture of an amorphous phasecomprising silicon and a nanocrystalline phase comprising anintermetallic compound with tin, indium, and the sixth element; andproviding a cathode and an electrolyte, wherein the electrolyte is inelectrical communication with both the cathode and the anode, whereinthe nanocrystalline phase comprises crystalline materials having amaximum dimension of about 5 to about 50 nanometers.
 18. The method ofclaim 17, wherein providing the alloy composition comprises meltspinning the silicon, aluminum, tin, the transition metal element, andthe sixth element.
 19. The method of claim 17, wherein providing thealloy composition comprises initially forming a totally amorphousprecursor material and then annealing the precursor material to preparethe mixture of the amorphous phase and the nanocrystalline phase. 20.The method of claim 17, wherein providing the alloy comprises: forming aprecursor material that comprises (i) amorphous material; (ii) thenanocrystalline phase comprising tin, indium, and the sixth element;(iii) at least one additional crystalline phase that contains elementaltin, elemental indium, binary tin-indium, or a combination thereof; andannealing the precursor material to remove the additional crystallinephase.
 21. The method of claim 17, wherein the nanocrystalline phase issubstantially free of silicon.
 22. An alloy composition comprising a)silicon in an amount of 35 to 70 mole percent; b) aluminum in an amountof 1 to 45 mole percent; c) a transition metal in an amount of 5 to 25mole percent; d) tin in an amount of 1 to 15 mole percent; e) indium inan amount up to 15 mole percent; and f) a sixth element comprisingyttrium, a lanthanide element, an actinide element, or a combinationthereof in an amount of 2 to 15 mole percent, wherein each mole percentis based on a total number of moles of all elements except lithium inthe alloy composition; and the alloy composition is a mixture of anamorphous phase comprising silicon and a nanocrystalline phasecomprising an intermetallic compound with (1) tin, (2) indium, and (3)the sixth element, wherein the nanocrystalline phase comprisescrystalline materials having a maximum dimension of about 5 to about 50nanometers.